Greenfield Compressor Station Engineering and Design
Oil & Gas | Midstream
Location | Utah
The Challenge
The client required full engineering, design, and project management support for the development of a new greenfield gas gathering compressor station in Utah. The facility needed to accommodate immediate production demands while maintaining flexibility for future expansion from two to four compressor units. The project’s complexity stemmed from integrating multiple process systems—including gas compression, dehydration, emissions control, and liquids handling—into a single cohesive design. Ensuring constructability, operational safety, and regulatory compliance while coordinating across all engineering disciplines posed additional challenges.
The Solution
Halker provided comprehensive multidisciplinary engineering services encompassing process, mechanical, civil, structural, electrical, and instrumentation disciplines to deliver a fully integrated and expandable compressor station design. The initial facility included two Waukesha 7044 S5 three-stage compressors with vertical coolers, designed for seamless expansion to four units. Major process systems included a slug catcher, discharge coalescer, H₂S scavenger system, TEG contactor, BTEX condenser, pig launcher, API 12F storage tanks, a station flare, vapor combustor, and advanced control systems.
Halker’s process engineers performed equipment sizing, developed P&IDs, material and energy balances, and verified relief system designs. The civil and structural teams designed site grading, drainage, access roads, and equipment foundations using a combination of drilled piers and shallow foundations. Structural steel platforms, handrails, and pipe supports were detailed to meet all operational and maintenance needs. Mechanical and piping engineers produced isometric piping drawings, CADWorx 3D models, and detailed specifications to ensure proper equipment integration and efficient layout.
Electrical and instrumentation engineers developed one-line diagrams, load studies, and area classification plans; designed lighting, grounding, and heat tracing systems; and provided I/O lists, wiring schematics, and control system documentation. The facility’s control and SCADA systems were built on Allen-Bradley PLCs and Wonderware HMIs, with Halker providing commissioning support for I/O loop checks, site acceptance testing, and startup activities.
Throughout the project, Halker managed procurement deliverables including bills of materials, equipment data sheets, and vendor proposal reviews. Regular progress meetings and milestone tracking ensured alignment with the client’s schedule and technical objectives. The result was a fully compliant, safe, and expandable compressor station design that met the client’s current operational requirements while providing the flexibility for future growth.